Offset igniter assembly

ABSTRACT

A gas burner assembly for connection to a source of gas is provided. The gas burner assembly includes a burner body defining an opening therethrough and a generally circular outer periphery. The outer periphery includes a recess therein. The gas burner additionally includes a bracketing unit secured to the burner body and including a igniter holder and at least one igniter being concentric about a vertical axis and positioned within at least one of the recess and the igniter holder. The igniter includes an ignition element that is adjustably positioned to provide an optimal radial distance from the burner body, and wherein the gas burner assembly is configured to operatively accommodate a variety of igniter styles.

BACKGROUND OF THE DISCLOSURE

The following disclosure relates generally to gas burners, and more particularly to ignition elements for igniting the fuel gas on the gas burners. The present disclosure finds particular application in accommodating a variety of ignition elements within a single family of burners.

Traditionally gas burner cook tops include ignition devices that generate a spark to ignite a burner when applicable fuel valves are opened, delivering fuel to the burner. Increasingly, however, the spark ignition devices are being replaced by ceramic hot surface ignition devices to ignite burners more reliably. Rather than relying on a spark, the ceramic hot surface igniter includes an element that generates a sufficient amount of heat to ignite the gas supplied to the burner. The ceramic hot surface igniter is essentially a hot filament and, as opposed to a spark, makes no noise and can be left on constantly such that a user can re-light the flame should it extinguish.

The different types of ignition devices used for gas burners depend primarily on customer preference, price point, and compatibility with existing burners. Each type of ignition device has a particular position in relation to a burner for optimal performance. Therefore, the optimal location of a hot surface ignition device may not be the same as that needed for a spark electrode, depending on the burner design and other design limitations. A traditional solution would be to use different brackets and supports for both a spark and hot surface igniter to secure each at their respective optimal positions. However, having to replace burner parts when changing ignition styles increases the number of parts to manage throughout the production and manufacturing chain, thereby increasing cost and complexity.

Accordingly, there is a need for an ignition positioning system that can allow a burner assembly to accommodate each type of ignition device without the need for unique burner system parts.

SUMMARY OF THE DISCLOSURE

A gas burner assembly for connection to a source of gas is provided. The gas burner assembly includes a burner body defining an opening therethrough and a generally circular outer periphery. The gas burner additionally includes a bracketing unit secured to the burner body and including an igniter holder and at least one igniter being concentric about a vertical axis and positioned within the igniter holder. The igniter comprises an ignition element that is adjustably positioned to provide an optimal radial distance from the burner body, and wherein the gas burner assembly is configured to operatively accommodate a variety of igniter styles.

An ignition device for use with a gas burner assembly is provided. The igniter includes a generally cylindrical body substantially concentric about a vertical axis and an ignition element having an adjustable radial position in relation to the vertical axis. The radial position is dependent on an optimal gap distance from an associated gas burner. The ignition element preferably includes at least one of a spark wire and a silicon nitride hot surface.

A method for constructing a gas burner assembly is provided. The method includes coupling a burner body to an injet bracket, the burner body defining an opening therethrough and a generally circular outer periphery. The method further includes detachably mounting an igniter to the burner body, the igniter being generally concentric about a vertical axis, and adjustably locating an ignition element in relation to the vertical axis to provide an optimal gap between the ignition element and the burner body, wherein the burner assembly is configured to accommodate at least two different ignition element styles.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an oven range.

FIG. 2 is an exploded perspective view of a burner assembly.

FIG. 3 is a perspective view of a burner assembly having a hot surface igniter.

FIG. 4 is a perspective view of a burner assembly having a spark igniter.

FIG. 5 is an exploded perspective view of a burner assembly in accordance with one aspect of the present disclosure.

FIG. 6 is a side view of a hot surface igniter (top) and spark igniter (bottom) in accordance with one aspect of the present disclosure.

FIG. 7 is a perspective view of a spark igniter (top) and hot surface igniter (bottom) in accordance with another aspect of the present disclosure; and

FIG. 8 illustrates the gap differences between a hot surface igniter and a spark igniter in accordance with another aspect of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While methods and apparatuses are herein described in the context of a gas-fired cooktop, as set forth more fully below, it is contemplated that the herein described methods and apparatuses may find utility in other applications, including, but not limited to, gas heater devices, gas ovens, gas kilns, gas-fired meat smoker devices, and gas barbecues. In addition, the principles and teachings set forth herein may find equal applicability to combustion burners for a variety of combustible fuels. The description hereinbelow is therefore set forth only by way of illustration rather than limitation.

FIG. 1 illustrates an exemplary free standing gas range in which the herein described methods and apparatuses may be practiced. Range 10 includes an outer body or cabinet that incorporates a cooktop shown here as a generally rectangular cooktop 14. An oven, not shown, is positioned below cooktop 14 and has a front-opening access door 16. A range backsplash 18 extends upward of a rear edge 20 of cooktop 14 and contains various control selectors (not shown) for selecting operative features of heating elements for cooktop 14 and the oven. It is contemplated that the herein described methods and apparatuses is applicable, not only to cooktops which form the upper portion of a range, such as range 10, but to other forms of cooktops as well, such as, but not limited to, free standing cooktops that are mounted to a kitchen counter. Therefore, gas range 10 is provided by way of illustration rather than limitation, and accordingly there is no intention to limit application of the herein described methods and apparatuses to any particular appliance or cooktop, such as range 10, or cooktop 14.

Cooktop 14 includes, for example, four gas fueled burner assemblies 22 which are positioned in spaced apart pairs positioned adjacent each side of cooktop 14. Each pair of burner assemblies 22 is preferably surrounded by a recessed area 24 of cooktop 14. Recessed areas 24 are positioned below an upper surface 24 of cooktop 14 and serve to catch any spills from cooking utensils (not shown in FIG. 1) being used with cooktop 14. Each burner assembly 22 extends upwardly through an opening in recessed areas 24, and a grate 28 is positioned over each burner 22. Each grate 28 is positioned over each burner 22. Each grate 28 includes a flat surface thereon for supporting cooking vessels and utensils over burner assemblies 22 for cooking of meal preparations placed therein.

The construction and operation of the range heating elements, including cooktop gas burner assemblies 22, are believed to be within the purview of those in the art without further discussion, and as details of the range heating elements are generally beyond the scope of the herein described methods and apparatuses, further description is therefore omitted. Further it is contemplated that the herein described methods and apparatuses may find utility in combination with other heat elements besides range gas burners 22.

While cooktop 14 includes two pairs of grates 28 positioned over two pairs of burner assemblies 22, it is contemplated that greater or fewer number of grates could be employed with a greater or fewer number of burners without departing from the scope of the herein described methods and apparatuses.

FIG. 2 is an exploded perspective view of an exemplary burner assembly that can be used with the gas range of FIG. 1. The burner assembly includes a burner body 32, a solid base portion 34, and a cylindrical sidewall 36 extending axially from the periphery of base portion 34. A main gas conduit 38 having an entry area 40 and a burner throat region 42 is open to the exterior of burner body 32 and defines a passage that extends axially through the center of burner body 32 to provide fuel/air flow to the burner assembly 30. As used herein, the term “gas” refers to a combustible gas or gaseous fuel-air mixture.

Burner assembly 30 is mounted on a support surface 44, such as cooktop 14, of a gas cooking appliance such as a range or cooktop. A cap 46 is disposed over the top of the burner body 32, defining therebetween an annular main fuel chamber 48 and annular diffuser region (not shown). A torodial-shaped upper portion 50 of burner body 32, immediately bordering burner throat 42, in combination with cap 46 defines the annular diffuser region therebetween. Cap 46 can be fixedly attached to the sidewall 36 or other designated attachment point or can simply rest on sidewall 36 for easy removal. Burner assembly 30 also includes at least one ignition element 52 (not shown in FIG. 2) extending through an opening in base portion 34. In the exemplary embodiment, the body of the ignition element 52 is preferably fabricated from a ceramic material, although other suitable materials are applicable and contemplated herein.

FIGS. 3 and 4 illustrate two exemplary ignition elements, a hot surface igniter 54 (FIG. 3) and a spark igniter 56 (FIG. 4). The hot surface igniter 54 is preferably formed from a ceramic material and includes an ignition element 62. The hot surface igniter 54 preferably includes a shield 58 around the ignition element 62 to protect the fragility of the elements contained therein. The ignition element 62 is preferably made from a material such as silicon carbide or nitride, and as electricity passes through the igniter, the ignition element will glow red hot. Preferably, the ignition element 62 comprises silicon nitride, as it is more durable and reduces the concern of fragility. The spark igniter 56 includes an electrode surrounded by an insulator, preferably ceramic, with a spark wire 60 associated with the electrode for creating a spark and igniting the gas released within the burner assembly 22.

The gas burner assemblies 22, as shown in FIGS. 3 and 4, are generally circular with igniters 54, 56 disposed at a recessed portion 64 in the peripheral edge of a burner body 32. The position of an ignition element 60, 62 within an igniter 54, 56, in relation to the burner body 32 is critical for successful ignition. Each type of ignition element 60, 62 has a unique optimum distance, and often the optimal distances are different for hot surface igniters 54 and for spark igniters 56. Accordingly, until now, it has been difficult if not impossible to assemble a single family of burners 22 that can accommodate a variety of the different ignition technologies, since unless the position of the igniter is adjusted each time, the gap between the burner 22 and the actual ignition element 60, 62 will not be optimized. Traditionally, the replacement of ignition devices is achieved by providing different burner brackets and/or burner bodies to accommodate each style of technology. Accordingly, the present disclosure provides a method and apparatus that enables a single set of burner assemblies 22 to accommodate a variety of ignition elements by varying the gaps between the different ignition elements 60, 62 and the burner bodies 32, such that there is no need for additional mounting parts and/or different burner assemblies. Moreover, the present disclosure provides the ability to locate and index an igniter in a burner system such that 1) the cross section of the igniter at some point is asymmetrical, and 2) the radial distance of the axis of the igniter's ignition element (i.e. spark wire or silicon nitride hot surface) varies between the spark electrode style and the hot surface style.

With reference to FIG. 5, an exemplary burner assembly 22 is provided that can accommodate various ignition technologies without requiring the replacement of the burner or bracket parts. The burner assembly 22 includes a burner body 32 and burner cap 46 positioned atop a cooktop 14, similar to that provided in FIG. 2 above. A main gas conduit 38 extends through a hole in the cooktop 14 to meet an injet bracket 59 disposed on the underside of the cooktop 14. An ignition device 52 is generally positioned near the injet bracket 59. FIG. 5 shows the igniter 52 being disposed through a hole in the cooktop 14, such that the top head 70 of the igniter 52 remains above the cooktop and an igniter stem 72 extends into a holder located on the injet bracket. In an alternative configuration, the igniter may be located within the burner body itself.

FIGS. 6 and 7 show exemplary igniters having elongated, generally cylindrical bodies 68, the bodies comprising top head portions 70 and stem portions 72, extending downwardly therefrom. Generally, the top head portions have a generally greater diameter than the stem portions 72. Each igniter style, hot surface 54 (top) and spark 56 (bottom) may include similarly formed bodies, such that each style is configured to mate with a burner body 32 and bracket 59. The igniter stem 72 and top head 70 are generally concentric about a vertical axis A. When a traditional spark igniter 56 is mated with a burner assembly 22, the spark wire 60 is typically optimally positioned such that it is generally aligned along the vertical axis A. However, if it is desired to replace the spark igniter 56 with a hot surface igniter 54, it may be seen that the hot surface ignition element 62 has a different optimal gap distance than the spark wire 60. Accordingly, to facilitate an optimal gap distance when replacing an igniter with that having a different style ignition element on a single family of gas burners, the position of the ignition element 60, 62 is shifted within a ceramic body 68 by moving the ignition element 60, 62 a particular distance offset from the vertical axis of the ignition top head 70 and stem 72.

Particularly referring to FIG. 6, an exemplary spark igniter (bottom) is illustrated, which generally includes a spark wire 60 through the ceramic body 68 that is centered about the vertical axis A of the igniter. The ignition element 70, 72 of the hot surface burner 54 (top), however, is offset from the igniter body's vertical axis, not centered about the axis as seen in the spark igniter 56. The hot surface ignition element 62 may be offset from the axis in a location that provides the desired gap between the element 62 and the burner body 32. Accordingly, although different gaps are optimal for the spark igniter 56 and hot surface igniter 54, both types of technology may be used on the same burner assembly 22, as shown in FIG. 8.

The exemplary burner assemblies, shown in FIG. 8, include a hot surface igniter 54 (top), wherein the gap “x” between the hot surface ignition element 62 and the burner body 32 comprises a first distance. In essentially the same burner assembly 22, a spark igniter 56 (bottom) is provided having a gap “y” between the spark ignition element and the burner body that comprises a second distance, which in the exemplary depiction of FIGS. 6 and 7, is less than the first distance x. Accordingly, the same burner assembly 22 can accommodate both the spark ignition technology and the hot surface technology without requiring a different cook top and/or bracketing configuration. Rather, the igniter may simply be replaced with an igniter adjusted for the optimal gap, thereby saving in costs and production steps.

To properly locate and orient an ignition device 52 in relation to a burner body and ensure that an ignition element maintains its optimal gap, the ignition device may include a geometric key portion that ensures proper placement and eliminates potential rotation. Such a geometric key portion is achieved by several methods, such as by adding a flat surface amongst the cylindrical body 68, adding a groove to the body 68, or pressing the igniter on the bracket. The flat surface 66 provided on the body of the hot surface igniter 54 in FIG. 7 allows the igniter to be positioned and oriented in such a way that that it will not rotate and will continuously maintain the optimized position of the igniter with respect to the burner.

The disclosure has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the disclosure be construed as including all such modifications and alterations. 

1. A gas burner assembly for connection to a source of gas, said gas burner assembly comprising: a burner body defining an opening therethrough and a generally circular outer periphery; a bracketing unit secured to said burner body and including an igniter holder; and at least one igniter being concentric about a vertical axis and positioned within said igniter holder, said igniter comprising an ignition element, wherein said ignition element is adjustably positioned to provide an optimal radial distance from said burner body, and wherein said gas burner assembly is configured to operatively accommodate a variety of igniter styles.
 2. The gas burner assembly of claim 1, wherein said igniter comprises a ceramic body.
 3. The gas burner assembly of claim 1, wherein said outer periphery of said burner body comprises recess therein, said recess configured to accept said at least one igniter.
 4. The gas burner assembly of claim 1, wherein said ignition element comprises a spark wire that is either offset from or aligned with said vertical axis.
 5. The gas burner assembly of claim 4, wherein the radial distance of said ignition element comprises a distance of y.
 6. The gas burner assembly of claim 1, wherein said ignition element comprises a silicon nitride hot surface positioned one of offset from and aligned with said vertical axis.
 7. The gas burner assembly of claim 6, wherein said radial distance comprises a distance of x.
 8. The gas burner assembly of claim 1, wherein said igniter comprises a keyed body for rotational orientation to said burner body.
 9. The gas burner assembly of claim 8, wherein said keyed body comprises one or more of a groove and a flat surface among the cylindrical body.
 10. An ignition device for use with a gas burner assembly, said igniter comprising: a generally cylindrical body concentric about a vertical axis; and an ignition element having an adjustable radial position in relation to said vertical axis, said radial position being dependant on an optimal gap distance from an associated gas burner, wherein said ignition element comprises at least one of a spark wire and a silicon nitride hot surface.
 11. The ignition device of claim 10, wherein said body comprises a ceramic material.
 12. The ignition device of claim 10, wherein the radial position of said the spark wire is different than the radial position of said hot surface.
 13. The ignition device of claim 10, wherein said cylindrical body comprises a keyed portion configured to be particularly oriented with an associated burner assembly.
 14. The ignition device of claim 13, wherein said keyed geometry includes one or more of a groove and a flat surface amongst said cylindrical body.
 15. The ignition device of claim 10, wherein said ignition element comprises a silicon nitride hot surface positioned one of offset from and aligned with said vertical axis.
 16. The ignition device of claim 10, wherein said ignition element comprises a spark wire positioned one of offset from and aligned with said vertical axis.
 17. A method for constructing a gas burner assembly, said method comprising: coupling a burner body and to an injet bracket, said burner body defining an opening therethrough and a generally circular outer periphery; detachably mounting an igniter to at least said burner body, said igniter being generally concentric about a vertical axis; and adjustably locating an ignition element in relation to said vertical axis to provide an optimal gap between said ignition element and said burner body, wherein said burner assembly is configured to accommodate at least two different ignition element styles.
 18. The method for assembling a single burner unit of claim 17, further including providing said body with a keyed portion for particularly positioning said igniter within said holder.
 19. The method according to claim 17, wherein said igniter styles comprise one or more of a spark igniter and a hot surface igniter.
 20. The method according to claim 19, wherein accommodating a spark igniter comprises adjusting the radial position of said ignition element to align with said vertical axis.
 21. The method according to claim 19, wherein accommodating a hot surface igniter comprises adjusting the radial position of said ignition element to be a particular distance offset from said vertical axis. 